Axminster pile fabric and method for making the same



1967 R. J. CARRlGAN ETAL 3,354,914

AXMINSTER FILE FABRIC AND METHOD FOR MAKING THE SAME 2 Sheets-Sheet 1 Filed Jan. 6, 1966 Nov. 28, 1967 R. J. CARRIGAN ETAL 3,3 ,9

AXMINSTER FILE FABRIC AND METHOD FOR MAKING THE SAME Filed Jan. 6, 1966 2 Sheets-Sheet 2 United States Patent 3,354,914 AXMINSTER PILE FABRIC AND METHOD FOR MAKING THE SAME Raymond J. Carrigan, Thompsonville, and Wayne T. Harrison, Enfield, Conn, assignors to Bigelow-Sanford, Inc., Thompsonville, Cnn., a corporation of Delaware Filed Jan. 6, 1966, Ser. No. 519,097 6 Claims. (Cl. 139399) ABSTRACT OF THE DISCLOSURE Axminster loom and weaving method and Axrninster carpet having weftwise rows of I-tufts and other weftwise rows of U-tufts arranged according to a pattern, in which loom and method an additional cam, associated with the tube frame dip cam, is selectively operated in accordance with a pattern to apply a withdrawal motion to the tube frame to provide a shorter length of pile yarn to be turned up by the comb thereby forming J-tufts in certain predetermined weftwise rows.

The present invention relates to pile fabric floor covering and more particularly to a novel Axminster carpet or rug wherein the pile face comprises weftwise rows of U-tufts and other weftwise rows of J-tufts, distributed in accordance with a pattern, and to a method and loom for the manufacture of the same.

In Axminster fa'bric each pile tuft is form-ed by a short individual length of pile yarn looped about a weft to form two tuft legs, one on each side of the weft, extending above the backing to form the pile face. In traditional Axminster fabric all of the pile tufts are U-tufts, i.e., they have legs of equal length. The art has recently learned, as indicated in Reinhardt Patent 2,940,479, to make machine-made Axminster carpet wherein all of the pile tufts have only one leg or have one leg shorter than the other, i.e., are J-tufts, but in such fabric all of the weftwise rows, throughout the fabric, are alike.

The present invention provides an apparatus, method and product wherein the Axminster carpet or rug is provided with a pattern formed by variation, from row to row weftwise of the fabric, of the construction of the pile tuft as respects its being either a J-tuft or a U-tuft, such pattern being capable of variation in accordance with the desires of the designer.

Accordingly an object of the invention is to provide an Axminster pile fabric floor covering wherein certain weftwise rows of pile tufts are constituted of U-tufts and other weftwise rows are constituted of J-tufts.

Another object of the invention is to provide such an Axminster pile fabric floorcovering wherein the distribution of such weftwise rows of different character is in accordance with a pattern.

A further object of the invention is to provide an Axminster pile fabric floor covering wherein alternate weftwise rows are formed of U-tufts and the intermediate weftwise rows are formed of J-tufts.

Another object of the invention is to provide an AX- minster weaving process for the manufacture of such Axminster pile fabric floor covering.

Another object is to provide an Axminster loom adapted to practice such process.

Other objects, features and advantages of the invention will become apparent from the following description of an illustrative embodiment thereof in which description references are made to the accompanying drawings, wherein,

FIG. 1 is a side elevation, partly in section, of the modified Axminster loom of the invention;

FIG. 2 is a detail side elevation of a portion of the tube frame motion cam appearing in FIG. 1;

FIG. 3 is a vertical sectional view taken on line 33 of FIG. 2, and,

FIGS. 4, 5, 6 and 7 are diagrammatic warpwise vertical sectional views of the fabric at the weaving point in the loom, illustrating successive steps in the method of the invention.

In accordance with the method of the invention the weft-wise rows of U-tufts are formed in the conventional manner by wiping in the tubes of a tube frame between the binder warp threads, placing a holding weft shot in the shed, turning up the pile yarn ends depending from the tube frame about the holding weft shot, lifting the tube frame away from the fabric in a drawoif motion and severing the yarns, thus forming a weftwise row of pile tufts each having two legs of equal length looped about the holding weft. When a weftwise row of J-tufts is to be formed this is accomplished in accordance with the invention by applying to the tube frame at the end of the wipe-in motion an additional, novel, motion away from the fabric, to partially withdraw the pile yarn ends from the wefts and binder warp threads and turning the free ends of the pile yarns, while they are so withdrawn, about the holding weft. The subsequent drawoif motion and the severing operation are the same as those employed in forming the row of U-tufts. As a result of the novel withdrawal motion of the invention, the tuft leg formed by so turning up the free yarn end is shorter than the other leg formed in the same tuft, which other leg is the same in height as the legs formed in the conventional manner in the row of U-tufts. The result is a weftwise row of J-tufts.

To practice the method of the invention in the manufacture of machine-made Axminster carpet, the invention provides a simple modification of the conventional Axminster loom wherein a novel means is provided for selectively imparting to the tube frames, which supply the pile yarns, an additional withdrawal movement away from the wefts, preparatory to turning the pile yarn ends up about the holding weft, so that the length of pile yarn depending below the holding weft is less than normal and therefore, when turned up about the holding weft to form a tuft leg, results in a tuft leg of less than normal height. Conveniently such means for applying the additional withdrawal motion to the tube frame is mounted on the tube frame motion cam and comprises an adjustable segment at the wipe-in position and means for adjusting the segment selectively to provide such additional motion of the tube frame. Such tube frame motion cam makes one revolution per weftwise row, as is conventional. In its preferred form, the means for adjusting the segment is an additional cam mounted on the tube frame motion cam, together with means on the loom frame for adjusting said additional cam either into position to cause or into position not to cause such additional withdrawal motion, once during each revolution of the tube frame motion cam, whereby the tube frame motion cam is conditioned independently for each weftwise row to form that row either of U-tufts or of J-tufts. Preferably such additional cam is operated in accordance with a pattern so that the resulting weftwise rows of U-tufts and rows of J-tufts are distributed in the fabric in accordance with a pattern.

Accordingly, the product of the invention is characterized by the presence therein of weftwise rows of U-tufts and other weftwise rows of I-tufts which may be distributed in the fabric in accordance with a pattern. In one specific form of the product the weftwise rows of U-tufts alternate with the weftwise rows of J-tufts. All of the tuft legs on the same side of a single weft are approximately the same height and all of the legs on the other side of that weft are of the same height among themselves, which may be the same as or different from the height of the legs on the other side of that weft.

Referring now to the illustrative embodiments of the loom, process and product selected for purposes of illustration and shown in the drawing, and referring first to FIG. 1, the loom comprises conventional Axminster loom elements including two side frames 2 connected by cross girths, of which one is shown at 4, and by a breast beam 6, constituting the loom frame. A tube frame carrier chain 8 of considerable length brings a series of tube frames 10 to a position adjacent and above the weaving point at which they are removed from the chain 8 individually by the tube frame arms 12, lowered to the weaving position and manipulated therein to form a weftwise row of pile tufts. Binder warp threads 14 are supplied from a beam to the weaving point and are manipulated by heddles 16 to form a succession of sheds into which the weft are inserted by a conventional needle, not shown. Conventionally the needle lays two strands of weft at each pick. The term weft is used herein to designate the group of weft strands which functions in the fabric as a single weft unit, whether formed from one strand or from two strands or more. A reed 18 carried by a lay 20 is provided to beat the wefts to the fell of the fabric and a comb 22 is provided to turn the free ends of pile yarn depending from the tube frame tubes 10 upwardly about the holding weft to form the pile tufts. Knives 24, 26 function to sever the pile yarns extending from the tube frame to leave a length thereof in the fabric as a pile tuft. A main cam shaft 28 journalled in the side frames 2 carries a series of cams for operating the lay 20, the comb 22 and other conventional Axminster loom parts, and includes a tube frame motion cam disk 30 which alone is shown in the drawing as the invention relates particularly thereto. The parts of the loom heretofore described are of conventional Axminster loom construction.

The tube frame motion cam 30 operates to swing the tube frame arms 12 about their pivots 32 to move the tube frame upwardly and downwardly. The cam 30 for this purpose moves a cam follower roll 34 carried on an arm 36 pivoted on the loom frame at 38. The arm 36 is connected by links 40 to the tube frame arms. In its conventional motion and construction, the cam 30 raises the tube frame arms 12 to engage the tube frame 10 on the carrier chain 8, lowers the arms to remove the tube frame from the carrier chain and lower it to the leaving position where the tube frame tubes 10' and the free ends of pile yarns 42 depending therefrom are wiped between the binder warp threads 14 to leave a length of pile yarn 42 extending downwardly between the binder warp threads 14. After a holding weft has been inserted, the depending ends 42 are engaged by the comb 22 and turned to the left and upwardly about the weft to form a row of pile tuft legs. The invention modifies the cam 30 so that selectively, during the formation of predetermined weftwise rows, a novel upward withdrawal motion is imparted to the tube frame 10 which is at the weaving position whereby the yarn ends 42 extend downwardly below the weft for a lesser distance than normal with the result that when turned upwardly they form a row of pile tuft legs of lesser than normal height in that row. For this purpose a plate 44 mounted on the cam disk 30 at 46 has pivoted thereon at 48 (FIG. 2) an adjustable cam segment 50 having a camming surface at 52 engaging the cam follower roll 34. Adjustable cam segment 50 is adapted to be adjusted into different positions by means of an additional cam 54 mounted for rotation on a depending portion 44' of the plate 44 by means of a stud 56 threaded into the portion 44'.

Mounted on a plate 58, adjustably mounted on the cam disc 30 at 60, is a plunger 62 freely slidable in the plate 58 and having its lower end in engagement with the periphery of the cam 54 and its upper end in engagement with the adjustable cam segment 50, the segment being yieldably drawn downwardly into engagement with the plunger 62 by a spring 63. The cam 54 is provided with raised portions 64 and intervening low portions 66 as shown. When the cam 54 is in the position with a high portion 64 in contact with the plunger 62, the adjustable cam segment 58 is raised, as shown in its full line position in FIG. 2. When a low portion 66 is in contact with the plunger 62 the cam segment 50 is lowered into its dotted line position 50', FIG. 2. When in its lowered position, cam segment 50 lifts cam follower roll 34 to a normal height, indicated at 34', FIG. 2, but when in its raised position the cam segment 50 raises the follower 34 to a height higher than normal, as shown in full lines in FIG. 2.

To adjust the cam 54 into the desired position, a star wheel 68 is mounted on the stud 56 and connected to the cam 54 by a pin 70 whereby the cam 54 and star wheel 68 rotate together on the stud 56. The star wheel arms 72 four in number in this instance are adapted to be engaged by an operator 74 mounted on the loom frame so that during each rotation of the cam disk 30 the operator 74 engages one of the arms 72 to rotate the cam 54 one quarter of a revolution. Since there are two high portions 64 alternating with two low portions 66 on the cam 54 each step of the cam changes the cam from its high position to its low or vice versa.

Means is provided for moving the operator 74 out of the path of movement of the star wheel 68 in accordance with a pattern so that any desired succession of high positions or low positions of the cam 54 can be provided. As shown in FIG. 1, the operator 74 is hinged at 76 on a bracket 78 carried by the frame member 4. The operator 74 is adapted to be adjusted into its operative position shown in full lines or its inoperative position shown in dotted lines, in FIG. 1, by means of a link 80 pivoted at 82 to the operator 74 and fitting loosely at its lower end in a guide 84. A lever 86, pivoted on the loom frame at 88 and on link 80 at 90, has its pivot 90 biased upwardly by a spring 92, thus tending to maintain the operator 74 in its operative position. Movement of lever 86 is under the control of a pattern chain 94 containing low links 96 and high links 98. When a low link engages the lever 86 the lever remains in its full line position to maintain the operator 74 in operative position, but when a high link 98 engages lever 86, it is moved to its dotted line position to draw the link 80 downwardly and move the operator 74 downwardly into its dotted-line, inoperative position, in which it does not engage the star Wheel 68. The pattern chain 96 is driven by a chain 100 from the main cam shaft 28, whereby adjustment of the operator 74 is timed with the Weaving operation. The pattern chain 96 may be disabled, or be made entirely of low links 96, in which case the operator 74 will remain continuously in operative position, rotating star wheel 69 a quarter turn during each revolution of cam disk-30. As one revolution of cam disk 30 corresponds to the weaving of one weftwise row of pile tufts, the loom will weave rows of J-tufts alternating with rows of U-tufts, when the operator 74 remains continuously in operative position.

A weaving operation of this sort, wherein alternate rows of U-tufts and J-tufts are formed, is illustrated in FIGS. 4, 5, 6 and 7. In FIG. 4 the last completely formed weftwise row of tufts 102 is composed of U-tufts and is preceded by a row 104 of J-tufts. Following the formation of the row 102, the cam 54 is adjusted by the operator 74 to position a high portion 64 beneath the plunger 62. The tube frame tubes 18 accordingly are given an additional upward, withdrawal, motion from their dotted line position to the full line position so that the depending end of pile yarn 42 is moved from its dotted position to its full line position, wherein it' extends below the holding weft 106 for a distance which is less than normal. When the depending end is turned by the comb 22 to the left and upwardly about the holding weft 106 into the position of FIG. it accordingly extends upwardly less than the normal distance, forming a short leg 108. The pile yarn 42 is then severed at the normal height. The resulting row of pile tufts, FIG. 6, thus contains legs 108 which are shorter than normal and legs 110 which are of normal height. When the next tube frame is wiped in, FIG. 6, the cam 54 has been adjusted by the operator 74 to position a low portion 66 beneath the plunger 62 and, accordingly, the tube is not given any additional upward movement and the pile yarn end 42 depends below the holding weft 106 a normal distance so that when it is turned up by the comb into the position of FIG. 7 it forms a pile leg 112 of normal height. Severing of the pile yarn at the normal distance from the weft plane results in a new row of pile tufts having both legs of normal, full, height. The described operations are repeated to form succeeding rows.

The invention is applicable to the weaving of Axminster fabric of various constructions, including l-shot, 2-shot and 3-shot Axminster constructions.

Various modifications may be made by those skilled in the art without departure from the scope of the invention. For example, the two high portions of the cam 54 need not be of equal height, and the cam 54 may be provided with more than four lobes, of various heights, so that more than two different types of weftwise rows may be provided. Other variations within the scope of the invention will occur to those skilled in the art, and the appended claims are intended to embrace all such variations.

We claim:

1. The method of weaving an Axminster pile fabric floor covering having certain weftwise rows of pile tufts in the form of J-tufts and other weftwise rows of pile tufts in the form of U-tufts which comprises, in forming a weftwise row of pile tufts each having two legs of different lengths upstanding at opposite sides of a weft, the steps of forming a shed of binder warp threads, wiping the free ends of a weftwise row of pile yarns between said threads into said shed, partially withdrawing the pile yarns, inserting a weft into said shed, turning the free ends of the pile yarns, while the yarns are so withdrawn, about said weft to form the shorter one of said legs, and severing said pile yarns at points spaced farther from said weft than the free ends of said yarns to form the longer one of said legs, and forming a following weftwise row of pile tufts each having two legs upstanding at opposite sides of a weft, by repeating said steps but with the omission of said withdrawing step to form in the same fabric a following weftwise row of pile tufts having all its legs of equal length.

2. The method of claim 1 wherein the omission of said withdrawing step occurs in accordance with a pattern whereby certain weftwise rows of pile tufts having legs of equal length and other weftwise rows of pile tufts having legs of unequal length are arranged in the fabric in accordance with the pattern.

3. The method of claim 2 wherein said other rows alternate with said certain rows.

4. An Axrninster pile fabric floor covering comprising holding wefts, binder warp threads interwoven with said wefts, a weftwise row of pile tufts associated with each of said holding wefts, each tuft comprising a yarn looped below the weft and having its ends extending above the weft on opposite sides thereof to form a tuft leg at each side of the weft, certain of said rows having all legs therein of equal length, and other said rows in the same fabric having all their legs on one side of the weft of one length and all their legs on the other side of the weft of another length.

5. The fabric of claim 4 wherein said certain rows and said other rows are distributed in the fabric in accordance with a pattern.

6. The fabric of claim 5 wherein said other rows alternate with said certain rows.

References Cited UNITED STATES PATENTS 2,745,442 5/1956 Hennstadt 139-399 3,187,779 6/1965 Smiley et a1. 139-7 MERVIN STEIN, Primary Examiner. 

1. THE METHOD OF WEAVING AN AXMISTER PILE FABRIC FLOOR COVERING HAVING CERTAIN WEFTWISE ROWS OF PILE TUFTS IN THE FORM OF J-TUFTS AND OTHER WEFTWISE ROWS OF PILE TUFTS IN THE FORM OF U-TUFTS WHICH COMPRISES, IN FORMING A WEFTWISE ROW OF PILE TUFTS EACH HAVING TWO LEGS OF DIFFERENT LENGTHS UPSTANDING AT OPPOSITE SIDE OF A WEFT, THE STEPS OF FORMING A SHED OF BINDER WARP THREADS, WIPING THE FREE ENDS OF A WEFTWISE ROW OF PILE YARNS BETWEEN SAID THREADS INTO SAID SHED, PARTIALLY WITHDRAWING THE PILE YARNS, INSERTING A WEFT INTO SAID SHED, TURNING THE FREE ENDS OF THE PILE YARNS, WHILE THE YARNS ARE SO WITH DRAWN, ABOUT SAID WEFT TO FORM THE SHORTER ONE OF SAID LEGS, AND SEVERING SAID PILE YARNS AT POINTS SPACED FARTHER FROM SAID WEFT THAN THE FREE ENDS OF SAID YARNS TO FORM THE LONGER ONE OF SAID LEGS, AND FORMING A FOLLOWING WEFTWISE ROW OF PILE TUFTS EACH HAVING TWO LEGS UPSTANDING AT OPPOSITE SIDES OF A WEFT, BY REPEATING SAID STEPS BUT WITH THE OMISSION OF SAID WITHDRAWING STEP TO FORM IN THE SAME FABRIC A FOLLOWING WEFTWISE ROW OF PILE TUFTS HAVING ALL ITS LEGS OF EQUAL LENGTH. 